Scouring implement



8 1953 D. L. EASTMAN SCOURING. IMPLEMENT Filed Aug 3, 1950 INVENTOR. DON L. EASTMAN A TOQNEY have met with little Patented Aug. 25, 1953 Don L. Eastman,

.The Carborundum Company,

N. Y., a corporation 91' N. Y., minor to Niagara Falls, Delaware Application Augnst a, 1950, Serial No. 177,472

.4- Claims. (01. 51-298) This invention relates to abrading articles and particularly I tinuation-in-part of my former application Serial No. 725,361, filed January 30, 1947, now abandoned. i

The scouring implement of the present inven- 01 I SUCCESS.

.It is an object 01' the present invention to protory for the purpose,

2 vide an improved scouring implement which avoids many of the disadvantages of the materials heretofore offered for such use.

The abrasive articleor scouring implement of this invention differs sistant to deterioration by hot gents, and the acids, alkalies, etc. commonly iound in dishwater.

In accordance with the present invention an improved surface layer of granular abrasive material is ad-- hesively secured by means of a water-insoluble adhesive, the entire article being substantially un- With the commonly used household soaps and detergents.

In order that the present invention may be more clearly understood, reference is made to the drawings, in which,

Figure 1 is a perspective view of a scouring pad suitable for household scouring and cleansing purposes and made in accordance with the present invention; and

Figure 2 is a vertical sectional line 2-4 01' Figure 1.

The scouring pad shown in the drawing consists of a backing layer 4 of foam rubber about $5 in thickness to which a layer 5 view through the water, soap, deter! abrasive material is adhesively secured-by means of a layer of adhesive binder 6.

The described abrasive pad can be made as follows:

A layer of foam rubber in thickness is first given a primer coat of an adhesive composition such as one of those hereinafter set forth and dried for 2 to 5 minutes at 220 F. The side of the foam rubber which has received the prime coating of adhesive is then given a further coating of adhesive known as the making coat. While the making coat of adhesive is still tacky a layer of granular abrasive of the desired grit size, as for example a layer of 36 mesh grit size granular fused aluminum oxide, is deposited on the adhesively coated surface and a final sizing coat of adhesive applied over the top of the abrasive-coated surface. The coated product is then dried for 2 to 5 minutes at 220 F. followed by a final drying period of 30 minutes at 240 F. to set the adhesive to a non-tacky condition. The adhesive may be applied by roll coating, dip coating or spraying as may be desired. A thin film of adhesive can be applied, if desired, to the reverse side of the foam rubber pad to give it additional strength and wearing qualities.

The granular abrasive used in making scouring pads of the present invention, although specified above as being fused aluminum oxide particles of 36 grit size, can be any of those natural or artificially made mineral abrasive materials available on the market such as emery, various grades of fused aluminum oxide, silicon carbide, silica, garnet or the like and can be of any desired particle size.

The following are typical rubber-resin blended adhesive compositions which have been prepared and used with satisfactory results in the making of abrasive scouring implements in accordance with the present invention:

No. 1 formulation Parts Polychloroprene 900 Magnesium oxide 90 Wood rosin (Type FF) 45 Zinc oxide 45 Phenyl-beta-naphthylamine 9 Benzene 1690 Trichloroethylene 2850 Sulfur 2'1 Aniline-butyraldehyde 12 No. 2 formulation Parts Butadiene-acrylic nitrile copolymer 100 Durez Resin 12686 '15 Sulfur 3 Phenyl-beta-naphthylamine 1 Mercaptobenzothiazole 1 Zinc oxide 5 Liquid (refined coal tar oil fraction) plasticizer (such as Bardol) No. 3 formulation f Parts Butadiene-acrylic nitrile copolymer 100 Bakelite Resin Bit-47867 30 Sulfur 3 Phenyl-beta-naphthylamine 1 Mercaptobenzothiazole 1 Zinc oxide Liquid (refined coal tar oil fraction) plasticizer (such as Bardol) 5 No. 4 formulation Parts Polychloroprene Extra light calcined magnesium oxide 5 Sulfur 0.5 Benzothiazyl disulfide 1 Phenyl-beta-naphthylamme 1 Rosin 5 Bakelite Resin BR-1'l867 10- Durez Resin No. 12686, referred to in the above formulation No. 2, is an A stage, phenol-formaldehyde resin in lump form sold by the Durez Plastics and Chemicals, Inc. of North Tonawanda, New York.

Bakelite Resin BEL-17867, referred to in formulations Nos. 3 and 4 above, is a liquid A stage, phenol-formaldehyde resinous condensation product sold by the Bakelite Corporation of Bloomfield, New Jersey, under the aforesaid trade-mark designation.

In each formulation the base stock is prepared by milling together all the ingredients on standard rubber rolls until a homogeneous mixture is obtained. If it is desired to make only a small batch of the adhesive, the ingredients with the exception of the resin are first milled together on standard rubber rolls and the resin then added and blended into the mass in a Banbury mixer. The resulting blend of materials is then dissolved in a suitable solvent such as methyl ethyl ketone, methyl isobutyl ketone, benzene and trichloroethylene, or the like in suflicient amount to produce an adhesive solution of the desired consistency. For example, in preparing an adhesive solution from one of the base stock formulations above set forth the following proportions are found to provide adhesives of suitable consistency:

Per cent Base stock 30 Methyl ethyl ketone "70 There are a number of commercial adhesive products of the above blended rubber-resin type which I have found available on the market and. which are suitable for use in carrying out the present invention. These commercial adhesives are basically a resin-modified rubber base stock, including various conventional modifying agents such as vulcanizers, antioxidants, accelerators and the like, dissolved or suspended in a vehicle or solvent such as methyl ethyl ketone, methyl isobutyl ketone, benzene or trichloroethylene, or other comparable solvent. Among the commencially available adhesives which I have found can be used satisfactorily for theproduction of my scouring pads are the following:

Du Pont No. 4665 adhesive, made and sold by E. I. du Pont de Nemours 8: Company of Wilmington, Delaware, and which is a butadieneacrylonitrile copolymer blended with a phenol aldehyde resinous condensation product in the proportion of about 70 parts of the said copolymer to 30 parts of the phenolic resin dissolved in a suitable solvent.

Du Pont No. 4678 adhesive, made and sold by E. I. du Pont de Nemours 8: Company of Wilmington, Delaware, and which is also satisfactory is basically similar in composition and general properties to Du Pont No. 4665 adhesive.

Pli-O-Bond adhesive, made and sold by the U. S. Blywood Company, is a resin-modified butadiene acrylic nitrile copolymer rubber dissolved in about 20% of methyl ethyl ketone.

The term rubber as used herein in the specification or the claims as applied to the rubber roprene, butadiene-acrylonitrile copolymers, buconstituent of the adhesive used for securing the tadiene-styrene copolymers and other types of abrasive particles to the foam rubber backing is synthetic rubbers or elastomers either alone or intended to include not only natural rubber but blended in various proportions with one another also include the various synthetic rubbersor elasor with a natural rubber latex.

tomers available on the market such as buta- Having described the invention, it is desired diene-acrylonitrile copolymers, butadiene-styto claim:

rene copolymers, polychloroprene and other types 1. A scouring implement comprising a foam of synthetic rubber materials. rubber backing and a single layer of abrasive The foam rubber or latex team which constil0 granules substantially one grit size in thickness tutes the backing or base layer of the scouring adhesively secured thereto by means of a water articles of the present invention is prepared diinsoluble adhesive having permanent flexibility with the desired vulcanizing agent and other inrubber backing being of sufiicient thickness to two processes, 2. A scouring implement comprising a foam rubber backing of sufficient thickness to impart 5:; gig 8 nothing process or compressibility and handling strength to the ardistinguished from either chemically blown secured thereto by means of a thermosetting Sp ge rubbers or expanded rubbers which are resin-modified rubber base adhesive.

considerably different. By contrast, chemically 5 3. A scouring implement comprising a foam Such foam rubbers or latex foam materials are stantially one grit size in thickness adhesively to be blown sponge rubber is made from solid slab rubrubber backing of sunicient thickness to impart her which is compounded with a blowing agent compressibility and handling strength to the arand the resulting compound baked like a cake. e and a, single layer of abrasive granules suban azo compound, decomposes to form a gas secured thereto by means of a water-insoluble excess of blowingagent is not employed a closed ness, a superposed layer of thermosetting resinchemically blown sponge rubbers or expand d 4o layer thereby, said adhesive and base layers bescouring devices of the herein described type.- perature of dishwasher, and to the soaps, deterh f r w n reference is m to a m gents, oils, fats, greases, solvents and chemicals rubber in the specification or claims it is intendfound therein.

ed to exclude from that term the various chem- DON L. EA 'I' N, ically blown or expanded sponge rubbers.

Where reference is made herein to the use References Cited in the file of this patent of foam rubber as the backing material it is TENTS intended to include not only foam rubber made UNITED STATES PA from a natural rubber latex but to also include Number Name Date foam rubber materials composed of or containing 60264 Sawyer 1866 the various synthetic rubber latices in foamed 290L911 wooddeu at May 1935 condition such as the foamed latices of polychlo- 2336597 Hatch 1941 2,339,547 Carter Jan. 18, 1944 

1. A SCOURING IMPLEMENT COMPRISING A FOAM RUBBER BACKING AND A SINGLE LAYER OF ABRASIVE GRANULES SUBSTANTIALLY ONE GRIT SIZE IN THICKNESS ADHESIVELY SECURED THERETO BY MEANS OF A WATER INSOLUBLE ADHESIVE HAVING PERMANENT FLEXIBILITY AND ELONGATION, SAID ADHESIVE COMPRISING A BLEND OF RUBBER, AND THERMOSETTING RESIN, SAID FOAM RUBBER BACKING BEING OF SUFFICIENT THICKNESS TO IMPACT COMPRESSIBILITY AND HANDLING STRENGTH TO THE ARTICLE. 